Method of forming a linear panel from multi-layer panel material assemblies

ABSTRACT

In one aspect of the present subject matter, a method of forming a linear panel includes drawing a multi-layer panel material assembly having differing inner and outer material layers along a processing path. The method also includes heating the panel material assembly. In addition, the method includes forming the heated panel material assembly into a desired shape as the assembly is drawn along the processing path. Additionally, in another aspect of the present subject matter, a linear panel includes a body formed from a multi-layer panel material assembly having differing inner and outer material layers.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is based upon and claims the right of priorityto U.S. Provisional Patent Application No. 62/730,265, filed Sep. 12,2018, the disclosure of which is hereby incorporated by reference hereinin its entirety for all purposes.

FIELD

The present subject matter relates generally to the manufacture oflinear panels, and, in particular, to methods for manufacturing linearpanels formed from multi-layer panel material assemblies havingdiffering inner and outer material layers.

BACKGROUND

Linear panels formed from metals, such as aluminum, are known in theart. Linear panels have a length which is substantially greater thantheir width, the length generally being at least twice the width of thepanel and typically five or more times the width of the panel.

Linear panels formed from a metal have the advantage of being relativelylight and flame-retardant. However, such panels do not generally exhibitfavorable acoustic characteristics. It will be appreciated that, in manycircumstances, it might be desirable to provide a ceiling or wall havinggood sound-absorbing properties. Such a need might be addressed by theprovision of non-metallic or only partially metallic panels. However,improved techniques are needed for manufacturing such panels.

Accordingly, improved methods for manufacturing non-metallic or onlypartially metallic panels, such as panels formed at least partially fromfibrous materials, that provide one or more enhanced or desiredproperties as compared to conventional metallic panels would be welcomedin the technology.

BRIEF DESCRIPTION

Aspects and advantages of the present subject matter will be set forthin part in the following description, or may be obvious from thedescription, or may be learned through practice of the present subjectmatter.

In general, the present subject matter is directed to methods ofmanufacturing linear panels via an in-line process in which each panelis formed, at least in part, by an assembly of material layers.Specifically, in several embodiments, each panel is formed from amulti-layer panel material assembly including an inner material layerand an outer material layer, with the inner material layer differingfrom the outer material layer. In one embodiment, both the inner andouter material layers are formed from non-metallic materials (e.g.,fibrous materials).

In one embodiment, the method includes drawing a multi-layer panelmaterial assembly including differing inner and outer material layersalong a processing path. In one embodiment, the method also includesheating the panel material assembly. Additionally, in one embodiment,the method includes forming the heated panel material assembly into adesired shape as the assembly is drawn along the processing path.

Moreover, in one embodiment, the present subject matter is directed to alinear panel formed from a multi-layer panel material assembly includingdiffering inner and outer material layers. For example, in oneembodiment, the inner material layer is formed from a material having aforming temperature that is less than a forming temperature of amaterial used to form the outer material layer.

These and other features, aspects and advantages of the present subjectmatter will become better understood with reference to the followingDetailed Description and appended claims. The accompanying drawings,which are incorporated in and constitute a part of this specification,illustrate embodiments of the present subject matter and, together withthe description, serve to explain the principles of the present subjectmatter.

This Brief Description is provided to introduce a selection of conceptsin a simplified form that are further described below in the DetailedDescription. This Brief Description is not intended to identify keyfeatures or essential features of the claimed subject matter, nor is itintended as an aid in determining the scope of the claimed subjectmatter.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present subject matter, includingthe best mode thereof, directed to one of ordinary skill in the art, isset forth in the specification, which makes reference to the appendedfigures, in which:

FIG. 1 illustrates a cross-sectional view of one embodiment of a panelmanufactured in accordance with aspects of the present subject matter;

FIG. 2 illustrates a perspective view of the panel shown in FIG. 2;

FIG. 3 illustrates a schematic view of one embodiment of a process andrelated processing equipment for forming a multi-layer panel materialassembly configured for use within panels in accordance with aspects ofthe present subject matter;

FIG. 4 illustrates a schematic view of another embodiment of a processand related processing equipment for forming a multi-layer panelmaterial assembly configured for use within panels in accordance withaspects of the present subject matter;

FIG. 5 illustrates a schematic view of a further embodiment of a processand related processing equipment for forming a multi-layer panelmaterial assembly configured for use within panels in accordance withaspects of the present subject matter;

FIG. 6 illustrates a schematic view of one embodiment of an in-lineprocess and related equipment for forming a panel in accordance withaspects of the present subject matter, particularly illustrating theprocess incorporating aspects of a process for forming a multi-layerpanel material assembly used to manufacture the panel;

FIG. 7 illustrates a schematic view of another embodiment of an-lineprocess and related equipment for forming a panel in accordance withaspects of the present subject matter, particularly illustrating theprocess incorporating aspects of a process for forming a multi-layerpanel material assembly used to manufacture the panel;

FIG. 8 illustrates a perspective view of one embodiment of a pluralityof form blocks included within a heated mold in accordance with aspectsof the present subject matter;

FIG. 9 illustrates a perspective view of one embodiment of a coolingunit that may be utilized in accordance with aspects of the presentsubject matter for cooling panel materials;

FIG. 10 illustrates a perspective view of one embodiment of a pullingdevice that may be utilized in accordance with aspects of the presentsubject matter for pulling panel materials;

FIG. 11 illustrates a perspective view of one embodiment of a portion ofmanufacturing line in accordance with aspects of the present subjectmatter, particularly illustrating equipment for implementing an in-lineprocess for forming a panel, with the process incorporating aspects of aprocess for forming a multi-layer panel material assembly used tomanufacture the panel;

FIG. 12 illustrates a perspective view of one embodiment of a portion ofa heating device that may be utilized in accordance with aspects of thepresent subject matter for heating panel materials;

FIG. 13 illustrates a perspective view of one embodiment of a portion ofa bending station that may be utilized in accordance with aspects of thepresent subject matter for bending the panel materials;

FIG. 14 illustrates a perspective view of one embodiment of a portion ofa heating station that may be utilized in accordance with aspects of thepresent subject matter for heating panel materials;

FIG. 15 illustrates a perspective view of one embodiment of a portion ofa mold that may be utilized in accordance with aspects of the presentsubject matter when forming one embodiment of the disclosed panel;

FIG. 16 illustrates an end view of the mold shown in FIG. 15; and

FIG. 17 illustrates a perspective view of one embodiment of a coolingstage that may be utilized in accordance with aspects of the presentsubject matter for cooling panel materials.

DETAILED DESCRIPTION

In general, the present subject matter is directed to methods formanufacturing panels from a multi-layer panel material assembly.Specifically, in several embodiments, the multi-layer panel materialassembly includes two or more material layers, such as an inner materiallayer and an outer material layer. In one embodiment, the inner andouter material layers differ from each other, such as by being formedfrom differing materials and/or by having differing material properties(e.g., differing forming and/or melting temperatures).

By configuring the panel manufactured in accordance with aspects of thepresent subject matter as a multi-layer assembly of materials, theseparate material layers may be configured to perform or provideseparate functions. For instance, in one embodiment, the outer materiallayer is configured to provide one or more non-structural properties orqualities for the panel while the inner material layer is configured toprovide one or more structural properties for the panel, such as byconfiguring the outer material layer to serve as the primary decorativelayer of the panel while configuring the inner material layer to serveas the primary structural or shape-holding layer of the panel. Suchdivision of the panel functions into separate material layers may, inmany instances, allow for a more cost-effective panel to be producedwithout sacrificing performance or desired characteristics. In additionto aesthetic or decorative qualities (or as an alternative thereto), theouter material layer may also provide one or more non-structuralfunctional characteristics to the panel, such as sound-absorbingcharacteristics and/or flame-retardant qualities. Similarly, in additionto any structural characteristics, the inner material layer may alsoprovide one or more non-structural functional characteristics to thepanel, such as sound-absorbing characteristics and/or flame-retardantqualities.

In one embodiment, the inner material layer of the panel materialassembly is formed from a material(s) that has a forming/meltingtemperature that is less than a respective forming/melting temperatureof the material used to form the outer material layer of the panelmaterial assembly. In such an embodiment, the processing temperaturesused within the disclosed processes may, for example, be selected to beequal to or greater than the forming/melting temperature of the innermaterial layer, but less than the forming/melting temperature of theouter material layer. As a result, during the manufacturing process, thematerial of the inner material layer may be heated to a temperature ator above its forming and/or melting temperature to allow for desiredprocessing of the panel material assembly, such as when adhering theinner and outer material layers to each other to form the panel materialassembly and/or when shaping the panel material assembly into thedesired panel shape, while maintaining the desired properties of theouter material layer due to the processing temperature being lower thanits associated forming/melting temperature.

In several embodiments, the outer material layer of the panel materialassembly is formed from a material having one or more desiredproperties, such as a material having an aesthetically pleasing look ora material being acoustically open and/or sound-absorbing. Specifically,in one embodiment, the outer material layer is formed from a fibrousmaterial, such as a non-woven felt material or a woven fibrous material.For example, in one embodiment, the outer material layer comprises afibrous material formed from synthetic fibers, such as polyester fibers(PES), polyethylene terephthalate (PET) fibers, and/or any othersuitable synthetic fiber(s) and/or combinations thereof, or naturalfibers, such as wool or any other suitable natural fibers. As indicatedabove, in one embodiment, the material(s) selected for the outermaterial layer has a forming/melting temperature that is higher than theprocessing temperature(s) used during the panel-forming process As such,when the outer material layer is formed from a felt material, the highermelting temperature will prevent the fibers of the outer material layerfrom melting, thereby maintaining the decorative qualities of the layer(e.g., the felt-like appearance/texture) and/or the desired functionalqualities of the layer (e.g., desired sound-absorbing qualities and/orflame-retardant qualities).

Additionally, in several embodiments, the inner material layer is formedfrom a thermoformable material that allows it to become flexible orformable at the processing temperature(s) used during the panel-formingprocess and then hold its shape once the material is subsequently cooleddown. Additionally, in one embodiment, the inner material layer isformed from a thermoformable material that also exhibits one or moredesired non-structural properties (e.g., by being acoustically openand/or sound-absorbing and/or by having desired flame-retardantqualities), such as any suitable thermoformable fibrous material (e.g.,woven and non-woven materials formed at least in part by syntheticfibers, including bi-component fibers) or any suitable thermoformablefilm material (e.g., polymer films, such as perforated polymer films).Suitable bi-component fibers may, for example, fibers having an innercore formed from a first synthetic material having a first meltingtemperature and an outer layer or sheath formed from a second syntheticmaterial. As indicated above, in one embodiment, the material(s)selected for the inner material layer has a forming and/or meltingtemperature that is equal or less than the processing temperature(s)used during the panel-forming process. As such, during processing, theinner material layer may be heated to allow the panel material assemblyto be shaped or formed, as desired, and/or to allow the outer materiallayer to be adhered to the inner material layer.

In one aspect, a method of forming a linear panel is disclosed thatutilizes an in-line processing arrangement in which a panel materialassembly is drawn through a sequence of processing equipment duringwhich a corresponding sequence of operations or processing steps isperformed to manufacture a desired panel. For example, in oneembodiment, the method includes drawing the panel material assemblyalong a processing path, with the panel material assembly including aninner material layer and an outer material layer that differs from theinner material layer. The method also includes heating the panelmaterial assembly as the panel material assembly is drawn along theprocessing path and forming the heated panel material assembly into adesired panel shape. In addition, the method includes cooling the panelmaterial assembly after it has been formed into the desired panel shapeand as the panel material assembly is drawn along the processing path.

In one embodiment, the sequence of process equipment and thecorresponding sequence of operations or processing steps performed onthe panel material assembly corresponds to a continuous sequence ofequipment/operations, such as when the panel material assembly iscontinuously drawn through various processing stations positioned oneafter the other along the processing path. Alternatively, the sequenceof process equipment and the corresponding sequence of operations orprocessing steps performed on the panel material assembly may correspondto a non-continuous or interrupted sequence of equipment/operations.

In one embodiment, the method also includes forming the panel materialassembly as part of the in-line process while a downstream portion ofthe panel material assembly is being drawn along the processing path.For instance, in one embodiment, the method includes coupling separatestrips, webs, pieces, or lengths of material (referred to herein simplyas “strips” of material for the sake of convenience and without intentto limit) together to form the panel material assembly. Specifically, inone embodiment, the method includes coupling an inner strip of materialto an outer strip of material to form the inner and outer materiallayers, respectively, of the panel material assembly. Additionally, inone embodiment, the method includes heating the inner strip of materialto facilitate adherence of the inner strip of material to the outerstrip of material. For example, in one embodiment, the inner strip ofmaterial is heated to a processing temperature that is equal to orgreater than a melting temperature of the material forming the innermaterial strip to facilitate adherence of the inner and outer strips ofmaterial. Moreover, in one embodiment, the method includes pressing theinner and outer strips of material together to facilitate adherence ofthe inner strip of material to the outer strip of material.

In one embodiment, the panel material assembly further includes anintermediate layer disposed between the inner and outer material layers.In such an embodiment, the panel material is formed, for example, byheating the intermediate layer to a processing temperature (e.g., anactivation temperature of the intermediate layer) to facilitateadherence of the inner strip of material to the outer strip of material.

In one embodiment, the outer material layer is formed from a fibrousmaterial. For instance, in one embodiment, the outer material layer isformed from a non-woven or woven fibrous material formed at leastpartially from synthetic fibers, such as at least one of polyesterfibers or polyethylene terephthalate fiber, or natural fibers (e.g.,wool). In one embodiment, the outer material layer is formed from twodifferent types of fibers (e.g., two different synthetic and/or naturalfibers) and/or comprises bi-component polyester fibers.

In one embodiment, the inner material layer is formed from athermoformable material. For instance, in one embodiment, the innermaterial layer is formed from a thermoformable fibrous material, such asa woven or non-woven material formed at least partially from syntheticfibers. In one embodiment, the inner material layer is formed from twodifferent types of synthetic fibers and/or comprises bi-componentpolyester fibers. In another embodiment, the inner material layer isformed from a thermoformable film material, such as a perforated polymerfilm material. In an embodiment in which one or both of the materiallayers are formed from synthetic fibers, the fibers may haveflame-retardant properties.

In one embodiment, the method includes drawing the panel materialassembly through a heating station to heat the material assembly. Insuch an embodiment, the heating station may include a single heatingunit or device or multiple heating units or devices for heating thematerial. For instance, in a particular embodiment, the heating stationincludes at least one of a pre-heating unit, a heated mold, athermo-forming unit, and/or any other suitable heating device.Additionally, in embodiments in which the heating station includes twoor more heating devices, the heating station may be formed as acontinuous station (e.g., with the heating devices placed back-to-backalong the processing direction of the panel material assembly), or theheating devices may be spaced apart from one another along theprocessing direction of the panel material assembly.

In one embodiment, the method includes heating the panel materialassembly to a processing temperature as the panel material assembly isdrawn along the processing path. In one embodiment, the processingtemperature is greater than a forming temperature of the inner materiallayer and less than a forming temperature of the outer material layer.

In one embodiment, the method includes drawing the panel materialassembly through a plurality or series of form blocks of the heatedmold. In such an embodiment, each form block includes a differentcut-out shape such that, when the panel material assembly through theheated mold, the panel material assembly passes through each of theplurality of form blocks to incrementally change a shape of the panelmaterial assembly.

In one embodiment, the method includes drawing the panel materialassembly through a cooling station. For instance, in one embodiment, themethod includes drawing the panel material assembly through a pluralityof form blocks of the cooling station as a flow of air is directedtowards the panel material assembly.

In one embodiment, the method includes cutting the panel materialassembly into linear panel lengths. For instance, in one embodiment, thepanel material assembly is cut to length after the panel materialassembly has been formed and cooled.

In one embodiment, the panel material assembly is able to be formed intoa desired shape within a given temperature range selected based on thematerial properties of the inner material layer. For instance, in oneembodiment, the panel material assembly is able to be permanently formedinto the desired shape at a temperature that is at or greater than theforming/melting temperature of the inner material layer. However, indoing so, it is also desirable, in several embodiments, to select aprocessing temperature that is less than the forming/melting temperatureof the outer material layer. For instance, when the outer material layeris formed from a felt material including synthetic fibers, theprocessing temperature(s) can be selected to be less than theforming/melting temperature of the fibers to ensure that the outersurface or exterior of the panel formed by the outer material layerretains a fibrous, felt-like appearance. This is advantageous where thepanel is desired to have good sound absorbency, and may also be moreaesthetically desirable. If the panel material assembly was, instead,heated to a temperature such that most or all of the fibers melted andfused together, the resulting panel would have a smooth outer surface,and a greater density. Although this increases the strength of thematerial, it may reduce its ability to dampen sound and may also impactthe overall desired look or decorative qualities of the panel.

In another aspect, the present subject matter is directed to a method offorming a linear panel using an in-line processing arrangement in whicha layered material assembly is formed and drawn through a sequence ofprocessing equipment during which a corresponding sequence of operationsor processing steps is performed to manufacture a desired panel. Themethod includes coupling separate strips of material together to formthe layered material assembly including an inner material layer and anouter material layer as a downstream portion of the layered materialassembly is being drawn along a processing path, with the inner materiallayer differing from the outer material layer. In addition, the methodalso includes heating the layered material assembly as the layeredmaterial assembly is drawn along the processing path, and forming theheated layered material assembly into a desired panel shape.

In one embodiment, the sequence of process equipment and thecorresponding sequence of operations or processing steps performedcorresponds to a continuous sequence of equipment/operations, such aswhen the panel material assembly is continuously drawn through variousprocessing stations positioned one after the other along the processingpath. Alternatively, the sequence of process equipment and thecorresponding sequence of operations or processing steps performed onthe panel material assembly may correspond to a non-continuous orinterrupted sequence of equipment/operations.

In one embodiment, the separate strips of material comprise an innerstrip of material and an outer strip of material, with the inner stripof material forming the inner material layer of the panel materialassembly and the outer strip of material forming the outer materiallayer of the panel material assembly. Additionally, in one embodiment,the method includes heating the inner strip of material to facilitateadherence of the inner strip of material to the outer strip of material,such as by heating the inner strip of material to a processingtemperature that is equal to or greater than a melting temperature ofthe material forming the inner material strip. Moreover, in oneembodiment, the method includes pressing the inner and outer strips ofmaterial together to facilitate adherence of the inner strip of materialto the outer strip of material.

It should be appreciated that, in several embodiments, the variousprocessing steps of the disclosed methods, including, but not limitedto, heating the material, forming the material, and cooling thematerial, may be performed in a variety of different ways and/or usingany combination of suitable manufacturing equipment, devices, and/orcomponentry. For instance, aspects of the various example methodsdescribed herein may be combined or interchanged with other aspects tovary the manufacturing method used to form a given panel.

It should be also appreciated that the disclosed methods allows forpanels to be manufactured that exhibit enhanced or improved propertiesover conventional metallic panels. For instance, the , the panels formedusing the disclosed methods may have various desired decorativequalities while also exhibiting sufficient strength and/or rigidity toallow the panels to be used in any number of different applications,including use as ceiling panels or wall panels and/or in other suitableapplications for linear panels. Moreover, the disclosed method furtherallows for the resulting panels to have various other non-structuralfunctional qualities, such as improved sound-absorbency and/or desiredflame-retardant properties.

Additionally, it should be appreciated that the present subject matteris also directed to linear panels manufactured or formed in accordancewith one or more aspects of the methods described herein. For example,in one embodiment, a linear panel manufactured in accordance with one ormore of the disclosed methods includes a panel body formed from amulti-layer panel assembly having an inner material layer and an outermaterial layer, with the inner material layer defining an outer surfaceof the body and the outer material layer defining an outer surface ofthe body. In one embodiment, the body includes a panel wall and firstand second sidewalls extending outwardly from the panel wall.Additionally, in one embodiment, each of the first and second sidewallsis bent at an edge portion of the body to form respective first andsecond flanges. Moreover, in one embodiment, the inner material layer ofthe body is formed from a material having a forming temperature that isless than a forming temperature of a material used to form the outermaterial layer of the body.

Moreover, it should be appreciated that, although the variousmanufacturing processes disclosed herein will generally be described asbeing performed in a particular order for purposes of illustration anddiscussion, the processes are not limited to any particular order orarrangement. One skilled in the art, using the disclosures providedherein, will appreciate that various process steps disclosed herein canbe omitted, rearranged, combined, and/or adapted in various ways withoutdeviating from the scope of the present disclosure.

Referring now to the drawings, FIGS. 1 and 2 illustrate example views ofone embodiment of a panel 50 manufactured or made in accordance withaspects of the present subject matter, particularly illustrating both across-sectional view of the panel 50 (FIG. 1) and a perspective view ofthe panel 50 (FIG. 2). As shown, the panel 50 generally has asubstantially “U”-shaped cross-section, and is formed by a panel body 51including a central panel wall 52 and first and second side walls 54, 56extending outwardly from the central panel wall 52, with each of thefirst and second sidewalls 54, 56 being bent at corresponding edgeportions 58, 60 of the sidewalls 54, 56 to form respective first andsecond flanges 62, 64. As particularly shown in FIG. 2, the panel body51 (and thus, the panel 50) has a length L, with the length L beingsubstantially greater than a width W or depth D of the panel 50.Additionally, in one embodiment, the flanges 62, 64 of the panel 50 areconfigured to be received into and retained by complementary-shapedrecesses in a panel carrier (not shown) to enable mounting of the panelson, for example, a ceiling or a wall.

In several embodiments, the body 51 of the panel 50 is configured as orincludes a multi-layer panel material assembly 80, with two or morematerial layers being assembled together to form the panel 50.Specifically, as shown in the illustrated embodiment, the panel materialassembly 80 forming the panel 50 includes both an inner material layer82 and an outer material layer 84. As shown in FIG. 1, the innermaterial layer 82 is positioned along the interior of the panel 50 andgenerally defines an inner surface 66 of the panel 50. Similarly, theouter material layer 84 is positioned along the exterior of the panel 50and generally defines an outer surface 68 of the panel 50. Byconfiguring the panel 50 as a multi-layer assembly of materials, theseparate material layers 82, 84 may be configured to perform or provideseparate functions, such as by configuring the outer material layer 84to provide the panel 50 with one or more desired non-structuralcharacteristics or qualities while configuring the inner material layer82 to provide the panel 50 with one or more desired structuralcharacteristics or qualities. For instance, in one embodiment, the outermaterial layer 84 may be configured as the primary decorative layer ofthe panel 50 while the inner material layer 82 may be configured as theprimary structural or shape-holding layer of the panel 50. Such divisionof the panel functions into separate material layers may, in manyinstances, allow for a more cost-effective panel to be produced withoutsacrificing performance or desired characteristics. For instance, thematerial properties of each of the separate material layers 82, 84 maybe individually selected to provide desired performance orcharacteristics associated with the intended function(s) of each layer.It should be appreciated that, in addition to any decorative qualities(or as an alternative thereto), the outer material layer 84 may alsoprovide one or more non-structural functional characteristics orqualities, such as sound-absorbing and/or flame-retardant qualities.Similarly, it should be appreciated that, in addition to any structuralqualities, the inner material layer 82 may also provide one or morenon-structural functional characteristics or qualities, such assound-absorbing and/or flame-retardant qualities.

In several embodiments, the outer material layer 84 is formed from afibrous material having one or more desired properties, such as afibrous material providing the panel with a desire facade or outwardfacing look and/or a fibrous material that is acoustically open and/orsound-absorbing. Specifically, in one embodiment, the outer materiallayer 84 is formed from a non-woven or woven fibrous material, such as afelt material. For example, the outer material layer 84 may comprise anon-woven or woven fibrous material formed from synthetic fibers, suchas polyester fibers (PES), polyethylene terephthalate (PET) fibers,and/or any other suitable synthetic fiber(s) and/or combinationsthereof, or from natural fibers, such as wool and/or any other suitablefibers. Additionally, in several embodiments, the material properties ofthe outer material layer 84 may be selected to allow for the panel 50 tobe manufactured in accordance with aspects of the panel-forming processdescribed herein. For instance, as will be described below, the outermaterial layer 84 may have a melting and/or forming temperature that ishigher than the processing temperature(s) used during the panel-formingprocess, thereby allowing the outer material layer 84 to maintain one ormore of its desired properties or characteristics, such as its outertexture and/or aesthetic appearance. For example, when the outermaterial layer 84 is formed from a felt material, the higher meltingtemperature will prevent the fibers of the outer material layer 84 frommelting, thereby maintaining the desired felt-like appearance/texturewhile also maintaining any desired sound-absorbing qualities of theouter material layer 84. In addition, the material properties of theouter material layer 84 may be selected such that, despite having amelting/forming temperature that is greater than the processingtemperature(s) used during the panel-forming process, the outer materiallayer 84 will still be flexible enough at such processing temperature(s)to allow the layer 84 to follow the shape of the inner material layer 82as it is being formed into the desired panel shape.

It should be appreciated that, as an alternative to a non-woven or wovenfibrous material, the outer material layer 84 may, in other embodiments,be formed from any other suitable material that allows such layer 84 toprovide the desired performance and/or characteristics around theexterior of the panel 50, such as any desirable aesthetic propertiesand/or any desired non-structural functional characteristics.

Additionally, in several embodiments, the inner material layer 82 may beformed from any suitable thermoformable material that allows it tobecome flexible or formable at the processing temperature(s) used duringthe panel-forming process, and then to hold its shape once the materialis subsequently cooled down. Additionally, in a particular embodiment,the inner material layer 82 may be formed from a thermoformable materialthat also exhibits one or more desired non-structural properties (e.g.,by being acoustically open and/or sound-absorbing and/or by exhibitingflame-retardant qualities), such as any suitable thermoformable fibrousmaterial or any suitable thermoformable film material. For instance,suitable thermoformable fibrous materials may include, but are notlimited to, non-woven fibrous materials (e.g., felt materials) and wovenfibrous materials. In such an embodiment, the non-woven and/or wovenfibrous materials may be formed, at least in part, from syntheticfibers, such as polyester fibers (PES), polyethylene terephthalate (PET)fibers, and/or any other suitable synthetic fiber(s) and/or combinationsthereof. Similarly, suitable thermoformable film materials may include,but are not limited to, polymer or plastic films. In such an embodiment,it may be desirable for the film to be configured as a perforated orsound-penetrating film, such as a perforated polymer film.

It should be appreciated that, similar to the outer material layer 84,the material properties of the inner material layer 82 may be selectedto allow for the panel 50 to be manufactured in accordance with aspectsof the panel-forming process described herein. For instance, given itsintended function, the inner material layer 82 may have a melting and/orforming temperature that is equal to or less than the processingtemperature(s) used during the panel-forming process (and, thus, lessthan the melting and/or forming temperature of the outer material layer84), thereby allowing the inner material layer 82 to be shaped or formedas desired. Additionally, as will be described below, by heating theinner material layer 82 to a processing temperature at or above itsmelting temperature, the surface of the inner material layer 82 maybecome “sticky” or tacky, thereby allowing the inner and outer materiallayers 82, 84 to be coupled or adhered to each other during formation ofthe panel material assembly 80 as part of the disclosed panelmanufacturing process.

It should also be appreciated that, when the inner material layer 82 isformed from a non-woven fibrous material, the fibers may, in certainembodiments, correspond to bi-component synthetic fibers, such asbi-component polyester fibers. In such embodiments, each fiber mayinclude an inner core formed from a first synthetic material (e.g., afirst polyester material) having a first melting temperature and anouter layer or sheath formed from a second synthetic material (e.g., asecond polyester material) having a second, lower melting temperature,thereby allowing the outer layer or sheath of each bi-component fiber tobe melted without melting the inner core. For instance, the firstmelting temperature may be greater than the processing temperature(s)used during the panel-forming process while the second meltingtemperature may be less than such processing temperature(s). As aresult, the sheath will be melted during processing to allow the innermaterial layer 82 to be shaped or formed as desired.

As particularly shown in FIG. 1, the panel 50 generally defines anoverall thickness (t). In one embodiment, the thickness of the outermaterial layer 84 is less than the thickness of the inner material layer82 such that the inner material layer defines a majority of thickness(t) of the panel 50. For instance, in one embodiment, a thickness ratioof the inner material layer 82 to the thickness of the outer materiallayer 84 may be greater than 1:1 in increments of 0.05. In anotherembodiment, the thickness ratio of the inner material layer 82 to thethickness of the outer material layer 84 may be less than 4:1 inincrements of 0.05. In yet another embodiment, the thickness ratio ofthe inner material layer 82 to the thickness of the outer material layer84 may correspond to any thickness ratio within a range of ratiosbetween 1:1 and 4:1 in increments of 0.05. For example, in a particularembodiment, the thickness ratio of the inner material layer 82 to thethickness of the outer material layer 84 may be 1.5:1 or 2:1 or 2.5:1.

It should be appreciated that, by configuring the disclosed panel 50 toinclude two separate material layers, the inner and outer materiallayers 82, 84 may be formed from different materials, thereby allowingspecific materials to be selected to achieve the desired panelproperties while reducing material costs. For example, in embodiments inwhich the inner material layer 82 is configured to serve as the primarystructural layer of the panel 50 and does not generally contribute tothe aesthetic qualities of the panel 50, such layer 82 may be formedfrom a less expensive material that still provides the desiredstructural qualities. In contrast, given that the outer material layer84 generally defines the outward facing surface of the panel 50 and,thus, contributes to the overall look and feel of the panel 50, suchlayer 84 may be formed from a more expensive material. Accordingly, byusing a dual-layer configuration, less of the outer, more expensivematerial is needed to form the panel 50 (e.g., as opposed to forming thepanel 50 entirely from the more expensive material in an attempt toachieve the desired structural and decorative qualities).

It should be appreciated that the the specific configuration of thepanel 50 described above and shown in FIGS. 1 and 2 is provided only asan example of a suitable panel configuration that may be formed usingthe disclosed panel manufacturing process. However, in general, those ofordinary skill in the art should appreciate that panels formed inaccordance with the methods and processes described herein may havevarious other shapes, dimensional configurations, and/or the like,depending, for instance, on the intended application and/or use of thepanels being formed.

Referring now to FIG. 3, a schematic view of one embodiment of a processand related processing equipment (generally designated by 100) forforming a multi-layer panel material assembly is illustrated inaccordance with aspects of the present subject matter. As will bedescribed below, the process (and related equipment) shown and describedwith reference to FIG. 3 may, in one embodiment, form part of an in-lineprocess for manufacturing panels in accordance with aspects of thepresent subject matter during which the multi-layer panel materialassembly is drawn through a given sequence of processing equipment toform a desired panel. Additionally, it should be appreciated that,although FIG. 3 will generally be described with reference to the panel50 and panel material assembly 80 described above with reference toFIGS. 1 and 2, the process and related processing equipment 100 maygenerally be used to manufacture multi-layer panel material assemblieshaving any suitable configuration for use in forming any suitablepanels.

As shown in FIG. 3, in the illustrated embodiment, the inner and outermaterial layers 82, 84 of the panel material assembly 80 are formed fromcorresponding elongated strips of material(s) 102, 104 configured to bestored on and unwound from corresponding reels 106, 108. As indicatedabove, the term “strip(s)” is used broadly herein without intent tolimit to refer to any suitable strip(s), web(s), piece(s) or otherlength(s) of material Specifically, the inner material layer 82 isformed from a first or inner elongated material strip 102 supplied froma first reel 106 while the outer material layer 84 is formed from aseparate, second or outer elongated material strip 104 supplied from asecond reel 108. As shown in FIG. 3, the elongated strips of material102, 104 are fed through a pair of press wheels 110 (e.g., in aprocessing direction, as indicated by arrow 112) configured to press theinner and outer material layers 82, 84 together to form the panelmaterial assembly 80. The panel material assembly 80 may then be drawnthrough the remainder of the processing equipment associated withforming the corresponding panel 50 (e.g., as indicated by box 118 inFIG. 3), various examples of which will be described below.

In one embodiment, the material strip 102 forming the inner materiallayer 82 is configured to be pre-heated prior to being assembledtogether with the outer material layer 84 to form the panel materialassembly 80. Specifically, as shown in FIG. 3, prior to being deliveredto the press wheels 110, the elongated material strip 102 is passedthrough a pre-heating station 114 configured to heat all or a portion ofthe elongated material strip 102 to a processing temperature at or abovethe melting temperature of the associated material, thereby allowing theouter surface(s) of the material strip 102 to become sticky or tacky. Asa result, when the inner material strip 102 is subsequently pressed intoand against the outer material strip 104 between the press wheels 110,the separate layers 82, 84 may adhere to each other, thereby forming thepanel material assembly 80.

It should be appreciated that, in one embodiment, the pre-heatingstation 114 may only be configured to heat a portion of the elongatedmaterial strip 102 forming the inner material layer 82 to a processingtemperature at or above its melting temperature. For instance, in oneembodiment, the heating station 114 may only be configured to heat theside of the elongated material strip 102 that is configured to beadhered or coupled to the outer material strip 104, such as a bottomside 116 of the material strip 102 in the embodiment shown in FIG. 3. Insuch an embodiment, the heat source(s) within the pre-heating station114 may, for example, only be located on the side of the elongatedmaterial strip 102 desired to be heated (e.g., the bottom side 116) toallow localized heating of the elongated material strip 102 withoutrequiring the entire strip 102 to be heated to the desired processingtemperature. Alternatively, the elongated material strip 102 may havenon-homogenous material properties such that the side of the elongatedmaterial strip 102 desired to be heated (e.g., the bottom side 116)heats up to the desired processing temperature prior to the opposed sideof the elongated material strip 102.

It should also be appreciated that the pre-heating station 114 maygenerally have any suitable configuration that allows it to heat theelongated material strip 102 to the desired processing temperature. Forinstance, in one embodiment, the pre-heating station 114 comprises aheated mold or heated plates which conduct heat to the elongated strip102 as it passes therethrough. In other examples, the pre-heatingstation 114 may instead blow hot air onto or through the elongatedmaterial strip 102, or may suck hot air through the strip 102, or mayradiate heat in the form of infrared radiation thereon, for example.

Additionally, it should be appreciated that, in other embodiments, anyother suitable equipment or structure (in addition or as an alternativeto the press wheels 110) may be utilized to couple the inner and outermaterial layers 82, 84 together to form the panel material assembly 80.For example, the stacked material layers 82, 84 may be passed throughone or more blocks or forming dies or through one or more pairs ofopposed plates that serve to push or compress the layers 82, 84together.

Referring now to FIG. 4, a schematic view of another embodiment of aprocess and related processing equipment (generally designated by 100′)for forming a multi-layer panel material assembly is illustrated inaccordance with aspects of the present subject matter. As will bedescribed below, the process (and related equipment) shown and describedwith reference to FIG. 4 may, in one embodiment, form part of an in-lineprocess for manufacturing panels in accordance with aspects of thepresent subject matter during which the multi-layer panel materialassembly is drawn through a given sequence processing equipment to forma desired panel. Additionally, it should be appreciated that, althoughFIG. 4 will generally be described with reference to the panel 50 andpanel material assembly 80 described above with reference to FIGS. 1 and2, the process and related processing equipment 100′ may generally beused to manufacture multi-layer panel material assemblies having anysuitable configuration for use in forming any suitable panels.

As shown in FIG. 4, similar to the embodiment described above withreference to FIG. 3, the inner and outer material layers 82, 84 of thepanel material assembly 80 are formed from separate first and secondelongated strips of materials 102, 104, respectively, configured to bestored on and unwound from corresponding reels 106, 108. However, unlikethe embodiment described above that includes a pre-heating station, theelongated material strip 102 forming the inner material layer 82 isconfigured to be heated and pressed simultaneously via the press wheels110. Specifically, as shown in FIG. 4, one or both of the press wheelsmay include heat source(s) 120 (e.g., a resistance-based heatingelement) provided in association therewith that is configured to heatthe elongated material strip 102 forming the inner material layer 82 toa processing temperature at or above its melting temperature, therebyallowing the inner and outer material layers 82, 84 to be adhered orcoupled to each other to form the panel material assembly 80 as they arecompressed between the press wheels 110. The panel material assembly 80may then be drawn through the remainder of the processing equipmentassociated with forming the corresponding panel 50 (e.g., as indicatedby box 118 in FIG. 3), various examples of which will be describedbelow.

As indicated above, the outer material layer 84 may have a meltingtemperature that is higher than the inner material layer 82. As aresult, the processing temperature associated with the press wheel(s)110 may, for example, be higher than the melting temperature for theinner material layer 82, but lower than the melting temperature for theouter material layer 84 to prevent undesirable melting of such outerlayer 84. Additionally, it should be appreciated that, if additionalheating is required, the heated press wheels 110 shown in FIG. 4 may,for example, be used in combination with a separate heat source, such asthe pre-heating station 114 described above with reference to FIG. 3.

As indicated above, in other embodiments, any other suitable equipmentor structure may be utilized to couple the inner and outer materiallayers 82, 84 together to form the panel material assembly 80 inaddition (or as an alternative) the press wheels 110. For example, thestacked material layers 82, 84 may be passed through one or more blocksor forming dies or through one or more pairs of opposed plates thatserve to push or compress the layers 82, 84 together. In such anembodiment, the block(s), forming die(s), and/or pair(s) of opposedplates may be heated to allow such component(s) to heat the elongatedmaterial strip 102 forming the inner material layer 82 to a processingtemperature at or above its melting temperature, thereby allowing theinner and outer material layers 82, 84 to be adhered or coupled to eachother to form the panel material assembly 80 as they are passed betweenand/or through the heated component(s).

Referring now to FIG. 5, a schematic view of a further embodiment of aprocess and related processing equipment (generally designated by 100*)for forming a multi-layer panel material assembly is illustrated inaccordance with aspects of the present subject matter. As will bedescribed below, the process (and related equipment) shown and describedwith reference to FIG. 5 may, in one embodiment, form part of an in-lineprocess for manufacturing panels in accordance with aspects of thepresent subject matter during which the multi-layer panel materialassembly is drawn through a given sequence of processing equipment toform a desired panel. Additionally, it should be appreciated that,although FIG. 5 will generally be described with reference to the panel50 and panel material assembly 80 described above with reference toFIGS. 1 and 2, the process and related processing equipment 100* maygenerally be used to manufacture multi-layer panel material assemblieshaving any suitable configuration for use in forming any suitablepanels.

As shown in FIG. 5, similar to the embodiments described above withreference to FIGS. 3 and 4, the inner and outer material layers 82, 84of the panel material assembly 80 are formed from separate first andsecond elongated strips of materials 102, 104, respectively, configuredto be stored on and unwound from corresponding reels 106, 108. However,unlike the embodiments described above, the panel material assembly 80includes an intermediate layer 122 disposed directly between the innerand outer material layers 82, 84. As shown in the illustratedembodiment, the intermediate layer 122 has been pre-applied to the sideof the material strip 102 forming the inner material layer 82 that isconfigured to be coupled to the material strip 104 forming the outermaterial layer 84 (e.g., the bottom side). Alternatively, theintermediate layer 122 may be pre-applied to the outer material strip104 or the intermediate layer 122 may be supplied from a separate reel.

In several embodiments, the intermediate layer 122 may correspond to anadhesive layer formed from any suitable type of adhesive. In suchembodiments, the intermediate layer 122 may be heated to activate theadhesive, thereby allowing the inner and outer material layers 82, 84 tobe adhered to each other. For instance, in the embodiment shown in FIG.5, the press wheels 110 are configured as heated press wheels (e.g., byincluding a heat source(s) 120 to allow the intermediate layer 122 to beheated to its activation temperature. In addition to the heated presswheels 110 (or as an alternative thereto), a separate pre-heatingstation may be utilized (e.g., similar to the embodiment shown in FIG.3) or separate heated equipment or components (e.g., one or more heateddies or form blocks and/or one or more pairs of heated plates) to heatthe intermediate layer 122 to its activation temperature. For instance,when the intermediate layer 122 is pre-applied to one of the materialstrips 102, 104, such material layer may be passed through the heatingstation together with the intermediate layer 122 to pre-heat theintermediate layer 122 to its activation temperature. Regardless, uponactivation, the intermediate layer 122 may facilitate adherence of theinner and outer material layers 82, 84 to each other to form the panelmaterial assembly 80. The panel material assembly 80 may then be drawnthrough the remainder of the processing equipment associated withforming the corresponding panel 50 (e.g., as indicated by box 118 inFIG. 3), various examples of which will be described below.

It should be appreciated that, when using an intermediate layer 122 toadhere the inner and outer material layers 82, 84 to each other, theactivation temperature for the intermediate layer 122 may, in severalembodiments, correspond to a processing temperature that is less thanthe melting temperatures for both the material layers 82, 84. In suchembodiments, the intermediate layer 122 may be activated without meltingeither material layer 82, 84 (particularly the inner material layer 82)when forming the panel material assembly 80.

As indicated above, the various implementations of the processes andrelated processing equipment described with reference to FIGS. 3-5 may,in several embodiments, form part of a larger in-line process (and,thus, a larger assembly of processing equipment) for manufacturingpanels in accordance with aspects of the present subject matter. In thisregard, various embodiments of processes and related processingequipment for manufacturing panels using a multi-layer panel materialassembly will now be described below.

In several embodiments, the disclosed panel-forming process utilizes aheating station configured at least in part as a heated mold. In such anembodiment, the multi-layer panel material assembly may be drawn throughthe heated mold, with the mold heating the panel material assembly toand/or maintaining the assembly at a given temperature selected, forexample, based at least in part on the material properties of the innermaterial layer. For instance, in one embodiment, the panel materialassembly may be heated to a processing temperature that is equal to orgreater than the forming temperature of the inner material layer, butless than the forming temperature of the outer material layer. As theelongated panel material assembly is drawn through the heated mold, themold deforms the heated assembly into a desired panel shape. In doingso, the panel material assembly may be drawn through the heated mold ata constant speed, with the speed of the material and the temperature ofthe mold optionally being controlled by a central control unit.

In one embodiment, the heated mold may deform the heated panel materialassembly on both elongate sides thereof, thereby forming a flange oneither side of the elongate strip. In one embodiment, the angle a(FIG. 1) between each flange and the elongate heated panel assembly isless than or equal to approximately 90° and/or greater than or equal toapproximately 25°, including any angles defined therebetween inincrements of 5°.

Additionally, in one embodiment, aspects of the disclosed process mayalso include pre-heating the panel material assembly to a given pre-heattemperature selected, for example, based at least in part on thematerial properties of the inner material layer. For example, in oneembodiment, the panel material assembly may be pre-heated to aprocessing temperature at or just below the forming temperature of theinner material layer. Such pre-heating may take place before the panelmaterial assembly enters the heated mold and may, for example, includeblowing heated air onto a surface of the panel material assembly (e.g.,the surface of the inner material layer) as the material assembly isdrawn through the heated air flow. Alternatively, heated air may besucked through the panel material assembly as the assembly is drawnthrough the pre-heating apparatus.

Additionally or alternatively, such pre-heating may include drawing theelongated panel material assembly through a pre-heating mold. In oneembodiment, the pre-heating mold may serve to heat the material only,and thus, does not act to deform the material. The pre-heating mold maybe part of the heated mold or may be a separate apparatus, such as aninfrared heating device or an air heated oven, for example.

Furthermore, in one embodiment, aspects of the disclosed process alsoinclude cooling the panel material assembly after the assembly exits theheated mold. Cooling the panel material assembly may comprise blowingair at or below ambient temperature onto or through the panel materialassembly as the assembly is drawn through the air flow. Alternatively,the air may be sucked through the panel material assembly as theassembly is drawn through the cooling apparatus.

Additionally or alternatively, the cooling process may include drawingthe panel material assembly through a cooling mold. In one embodiment,the cooling mold may serve to cool the material while maintaining itsformed shape. The cooling mold may be part of the heated mold or may bea separate apparatus.

Additionally, in one embodiment, aspects of the disclosed process mayalso include cutting the elongated panel material assembly into desiredlinear panel lengths. Cutting may be carried out by a guillotine, arotary blade, a heated wire, or by ultrasonic cutting apparatus, forexample. In one embodiment, cutting of the elongated panel materialassembly into desired linear panel lengths may be performance after theassembly has been cooled, such as to a temperature below the formingtemperature of the inner material layer.

Moreover, in several embodiments, the panel material assembly may bedrawn through the heated mold by rollers. In such embodiments, therollers may advantageously act to pull the panel material assemblythrough the heated mold, and may include features, such as spikes, tofacilitate such pulling. As an alternative, rollers with a stickysurface, or rollers made of or having a surface made of or covered by ahigh friction material, such as rubber or sand paper, may be usedinstead.

Further, in one embodiment, the heated mold may comprise a plurality ofform blocks each having a different cut-out shape such that, when thepanel material assembly passes through the heated mold, the assemblypasses through each of the form blocks in turn, thereby graduallychanging the shape of the assembly from a flat, elongated multi-layeredstrip to a linear panel having a desired panel shape. For instance, theform blocks may form all or part of a progressive heated mold used toprogressively or gradually form the panel material assembly into thedesired panel shape

For instance, FIG. 6 illustrates a schematic view of one embodiment ofan in-line process and related processing equipment (generallydesignated by 200) for manufacturing panels using a heated mold inaccordance with aspects of the present subject matter. In theillustrated embodiment, the process and related processing equipment forforming the multi-layer panel material assembly are indicatedschematically in FIG. 6 as a solid box labeled 100, 100′, 100*, with theoutput of such process/equipment corresponding to the panel materialassembly 80 (e.g., including the inner and outer material layers). Itshould be appreciated that the specific process/equipment represented bybox 100, 100′, 100* may generally correspond to any suitableprocess/equipment consistent with the disclosure provided herein, suchas any of the embodiments shown in FIGS. 3-5.

As shown in FIG. 6, in one embodiment, an initial downstream component202 of the processing equipment is configured to initially receive themulti-layer panel material assembly 80 (e.g., as represented by theelongated strip shown in FIG. 6 extending along the length of theprocessing path in the processing direction, as indicated by arrows112). For instance, the downstream component 202 may be positioneddownstream of the press wheels 110 (FIGS. 3-5) such that the panelmaterial assembly 80 is continuously drawn from its formation along theprocessing path in the processing direction 112. Thus, as a downstreamportion of the panel material assembly 80 is being drawn through thedownstream component 202 (and the remainder of the processing equipmentalong the processing path), an upstream portion of the panel materialassembly 80 is simultaneously being formed as part of the continuous,stream-lined process. It should be appreciated that, although FIG. 6illustrates an embodiment of the in-line process 200 in which the panelmaterial assembly 80 is drawn through a continuous sequence ofprocessing equipment to form the desired panel, the various processingsteps or operations associated with the in-line process 200 may,instead, be performed using a non-continuous or interrupted sequence ofprocessing equipment.

In one embodiment, the downstream component 202 configured to initiallyreceive the panel material assembly 80 may correspond to astrip-coupling apparatus configured to couple the end of one panelmaterial assembly 80 to the beginning of another panel material assembly80, as desired or needed (e.g., when switching out the coils containingthe inner and outer material layers), thereby enabling the materialassembly 80 to be continuously fed along the processing path from onestation (or piece of equipment) to another. In one embodiment, thestrip-coupling apparatus may staple, stick, tape, or sew the endstogether, or may couple the separate assemblies 80 together in any otherknown manner. For instance, in a particular embodiment, thestrip-coupling apparatus may comprise an ultrasonic welding apparatus,such as an ultrasonic knife, for simultaneous splicing and cutting thepanel material assemblies 80.

In the illustrated embodiment, the panel material assembly 80 is pulledthrough the heated mold by a pulling device 204, which may include oneor more rollers having spikes or a high friction material, such asrubber or sand paper, on the roller surface for gripping and pulling thematerial assembly 80. In one embodiment, in order to minimize stretchingof the panel material assembly 80, the pulling force exerted on theassembly by the pulling device 204 is carefully controlled and thetemperature of the assembly at the pulling device 204 is maintained ator below a given temperature to minimize stretching.

Optionally, a buffer (accumulator) 206 may be provided to readily enablethe panel material assembly 80 to be passed through the heated mold at aconstant speed, regardless of whether separate assemblies are in theprocess of being joined together or not. In one embodiment, it may bedesirable that the panel material assembly 80 be passed through theheated mold at a constant speed and that the temperature of the heatedmold be accurately controlled, as these two factors control the meltingof the inner material layer and hence the strength, shape, and/or otherproperties or characteristics of the finished panel.

As shown in FIG. 6, rollers 208 a, 208 b, 201 a, 210 b, 212 a, 212 b areprovided to pull the material assembly 80 through the buffer 206. Theserollers may have spikes or a high friction material, such as rubber orsand paper, on the roller surface for gripping and pulling the materialassembly 80 along the processing path in the associated processingdirection 112.

In the embodiment shown in FIG. 6, a molding unit 220 is provided thatincludes a pre-heating unit 222, a thermoforming unit 224, and a coolingunit 226. Alternatively, the molding unit 220 may only include thethermoforming unit 224, with the pre-heating and cooling units 222, 226being provided independent of and upstream/downstream of the moldingunit 220, respectively.

Pre-heating the panel material assembly 80 to a given pre-heattemperature selected, for example, based on the material properties ofthe inner material layer may help to strengthen the materials containedwithin the assembly 80 and may encourage any pre-shrinking of thematerials prior to entry into the thermoforming unit 224 of the moldingunit. For example, in one embodiment, the panel material assembly 80 maybe pre-heated to a temperature at or around the forming temperature ofthe inner material layer of the panel material assembly 80 (but lessthan the forming temperature of the outer material layer of the panelmaterial assembly 80). In general, it is desirable that shrinkage of thepanel material assembly 80 during manufacture of the panel is minimizedas the dimensions of the finished panel should permit the panel to besuccessfully mounted onto a carrier. Where the carrier has recessesconfigured to receive and retain the flanges of the panel, it will beappreciated that the size of the finished panel is particularlyimportant, and including a low temperature pre-heating of the panelmaterial assembly prior to formation of the panel advantageouslyprevents or limits excessive shrinking of the material assembly duringthe remainder of the manufacturing process. In order to control theeffects of any further shrinking of the panel material assembly duringmanufacture of the panel, the temperature to which the material assemblyis heated and the speed at which the material assembly proceeds alongthe processing path preferably is accurately controlled during the panelmanufacturing process

Additionally, by providing the pre-heating unit 222, the portion of thepanel material assembly 80 entering the thermoforming unit 224 can, forexample, be at the required forming temperature so that there is no needfor the material to be heated in the thermoforming unit prior to formingthe panel, thereby enabling the material assembly 80 to pass through thethermoforming unit at an increased speed, with the result that theproduction rate of the panels is increased. If no pre-heating isprovided, the panel material assembly 80 generally will need to beheated by the heated mold to reach the required forming temperaturebefore the material can be formed into a linear panel. In otherembodiments, a combination of pre-heating and heating within thethermoforming unit can be utilized to heat the panel material assembly80 during the forming process.

In one embodiment, the pre-heating unit 222 comprises a heated mold orheated plates which conduct heat to the elongated strip forming thepanel material assembly 80 as it passes therethrough. In other examples,the pre-heating unit 222 may instead blow hot air onto or through theelongated panel material assembly 80, or may suck hot air through theassembly 80, or may radiate heat in the form of infrared radiationthereon, for example.

In one embodiment, the thermoforming unit 224 comprises a heated moldfor thermoforming the panel into a desired shape, the shape beingdictated by the heated mold.

In one embodiment, the thermoforming unit 224 may be heated by hot oilwhich passes through channels in the mold to heat up the mold. The oilmay be heated by oil heaters 230, 232. The heaters 230, 232, andtherefore the temperature of the oil, are controlled by a centralcontrol unit 240. Heater 230 may be controlled to heat the oil to adifferent temperature than heater 232, so that the panel materialassembly 80 passing through the thermoforming unit 224 experiences astep-wise, or, alternatively, a gradual increase in temperature as itpasses through the thermoforming unit 224. Such an arrangement may beparticularly advantageous where there is no pre-heating unit provided.

In one embodiment, a separate oil heater 234 may also be provided forthe pre-heating unit 222, with the oil heater 234 similarly beingconfigured to be controlled by the central control unit 240. Thethermoforming unit 224 may be heated by other means, however providinghot oil in channels formed in the unit 224 is advantageous as the oilwill tend to retain heat longer than many other common liquids, such aswater, and can be used to accurately control the temperature of theheated mold and therefore the temperature of the panel material assembly80 passing therethrough.

In one embodiment, the heated mold heats and/or maintains thetemperature of the panel material assembly 80 at a given temperatureselected, for example, based on the material properties of the innermaterial layer. For instance, in one embodiment, the heated mold heatsand/or maintains the temperature of the panel material assembly 80 at aprocessing temperature greater than or equal to the temperature at whichthe material(s) of the inner material layer of the material assembly 80become soft and deformable, such as at a temperature at or above theforming temperature associated with the inner material layer. Ingeneral, overheating is not desirable—the forming temperature of theheated mold should be set such that the panel material assembly 80 isable to be deformed into the panel shape as it passes through the heatedmold while enabling the outer material layer of the material assembly 80to, for example, retain its desired properties or characteristics, suchas the desired decorative or aesthetic appearance (e.g., a fibrous,felt-like appearance when the outer material layer formed from a feltmaterial). In addition to such aesthetic considerations, the fibrousnature of the outer surface of the panel (i.e., as formed by the outermaterial layer) generally may allow for sound to be absorbed by thepanel, thereby enhancing the acoustic properties of the panel andattenuating unwanted noise in rooms in which the panel is installed. Assuch, the processing temperature within the heating mold is preferablyselected to be less than the forming temperature of the outer materiallayer of the panel material assembly 80.

As indicated above, a cooling unit 226 may form part of the molding unit220 or may be provided separately and downstream of the molding unit220. In general the cooling unit 226 may comprise a mold, form blocks,and/or a channel(s) through which the panel material assembly 80 passes.In one embodiment, fluid is supplied to the cooling unit 226 from fluidreservoir 236. The cooling unit may be in the form of a cooling moldthrough which the formed material assembly 80 passes. In this case, thefluid reservoir 236 may supply a cooled liquid, such as cooled oil, tochannels formed in the cooling unit 226. The cooling unit 226 ispreferably configured to support and maintain the shape of the panel andto cool the material assembly 80 such that the material assembly 80exiting the cooling unit is at a temperature of no more, for example,than a predetermined cool-down temperature set for the assembly 80. Thispermits the material(s) of the inner material layer be fixed intoposition and sets and stabilizes the final shape of the panel.

In an alternative embodiments, the fluid reservoir 236 supplies air tothe cooling unit 226. The air may be at ambient temperature or may becooled, and may be blown across, through or onto the surface of thepanel material assembly 80 passing through the cooling unit 226, or maybe sucked through the material assembly 80 as it passes through thecooling unit. In such an embodiment, the formed panel may, for example,be supported within a channel shaped to match the desired shape of thepanel while the material assembly 80 of the panel is being sufficientlycooled so as to fix the material(s) of the inner material layer intoposition and thereby set the final shape of the finished panel.

In one embodiment, the cooling process (as indeed the heating process)may be dependent upon the speed at which the panel material assembly 80is fed through the cooling (or heating) stages. For example, in oneembodiment, at speeds of approximately 2 meters/minute, passing thematerial assembly 80 through ambient air generally should be sufficientto permit satisfactory cooling thereof. However, at faster speeds of 10to 20 meters/minute, cooled air may need to be blown directly onto orsucked through the panel material assembly 80 in order to achievesatisfactory cooling of the material assembly given the fasterprocessing speed. Additionally or alternatively, the panel materialassembly 80 may be passed through a chilled mold. It should beappreciated that, in addition to the speed at which the materialassembly 80 is fed through the cooling (or heating stages), the actuallength of such stage(s) may also impact the cooling (or heating)process. For instance, for a longer cooling stage, ambient air may beused for cooling at faster processing speeds than for a significantlyshorter cooling stage.

Once the formed panel has cooled, it is able to be pulled withoutcausing unwanted stretching of the material, and the pulling device 204may be provided for this purpose. Finally, the cooled, elongated panelmay be cut into two or more elements of desired lengths by cutting unit242.

It should be appreciated that, in one embodiment, the pre-heating andcooling units may heat/cool the panel material assembly on one sideonly. For instance, it may be desirable for the panel material assemblyto only be heated/cooled along the side of the assembly containing theinner material layer.

In one embodiment, a packing table 244 may be provided at the downstreamend of the production apparatus.

Additionally, in one embodiment, an extractor unit 246 may also beprovided in the vicinity of the heated mold and/or any pre-heating orcooling units to remove surplus heat from the surrounding area.

In one embodiment, the material assembly 80 may be passed in theprocessing direction 112 through the processing equipment containedalong the processing path at speeds of greater than or equal toapproximately 10 meters/minute and/or less than or equal to 20meters/minute, including any speeds defined therebetween in incrementsof 1 meter/minute. Additionally, in one embodiment, the speed of transitand the temperature of the pre-heating unit 222, thermoforming unit 224,and/or the cooling unit 226 may be controlled by central control unit240.

In one embodiment, the central control unit 240 may be configured toimplement closed-loop control of one or more components of theprocessing equipment, such as the motor(s) associated with the reels106, 108 (FIGS. 3-5) and/or the press wheels 110 (FIGS. 3-5), thestrip-coupling apparatus 202, the accumulator 206, any suitablecomponent(s) of the molding unit 220, one or more of the heaters 230,232, 234, the pulling device 204, the cutting unit 242, and/or any othersuitable components or equipment utilized in forming a panel asdescribed herein. As such, the central control unit 240 may becommunicatively coupled to any number of sensors or other inputs devicesconfigured to provide operational feedback to the unit 240, such astemperature sensors, speed sensors, and/or the like. For instance,temperature sensors provided in operative association with thepre-heating unit 222, the thermo-forming unit 224, and/or the coolingunit 226 may be configured to provide temperature feedback to thecentral control unit 240, which may then allow the control unit 240 toadjust the processing temperature and/or processing speed, as necessaryor desired, of the panel material assembly 80 as it is drawn along theprocessing path in the processing direction 112.

It should be appreciated that, in one embodiment, the central controlunit 240 may correspond to any suitable processor-based device(s), suchas a computing device or any combination of computing devices. Thus, thecentral control unit 240 may generally include one or more processor(s)and associated memory devices configured to perform a variety ofcomputer-implemented functions (e.g., performing the methods, steps,algorithms, calculations and the like disclosed herein). As used herein,the term “processor” refers not only to integrated circuits referred toin the art as being included in a computer, but also refers to acontroller, a microcontroller, a microcomputer, a programmable logiccontroller (PLC), an application specific integrated circuit, and otherprogrammable circuits. Additionally, the memory may generally comprisememory element(s) including, but not limited to, computer readablemedium (e.g., random access memory (RAM)), computer readablenon-volatile medium (e.g., a flash memory), a floppy disk, a compactdisc-read only memory (CD-ROM), a magneto-optical disk (MOD), a digitalversatile disc (DVD) and/or other suitable memory elements. Such memorymay generally be configured to store information accessible to theprocessor(s), including data that can be retrieved, manipulated, createdand/or stored by the processor(s) and instructions that can be executedby the processor(s). For instance, computer-readable instructions may bestored within the memory that, when implemented the processor(s),configure the central control unit 240 to perform one or more of thecontrol functions described herein.

Referring now to FIG. 7, a schematic view of another embodiment of anin-line process and related processing equipment (generally designatedby 200′) for manufacturing panels using a heated mold is illustrated inaccordance with aspects of the present subject matter. In theillustrated embodiment, the process and related processing equipment forforming the multi-layer panel material assembly are indicatedschematically in FIG. 7 as a solid box labeled 100, 100′, 100*, with theoutput of such process/equipment corresponding to the panel materialassembly 80 (e.g., including the inner and outer material layers). Itshould be appreciated that the specific process/equipment represented bybox 100, 100′, 100* may generally correspond to any suitableprocess/equipment consistent with the disclosure provided herein, suchas any of the embodiments shown in FIGS. 3-5. Additionally, it should beappreciated that the process and related equipment shown in FIG. 7 aresimilar to the process/equipment described above with reference to FIG.6 and, thus, only notable differences between the two embodiments willbe described in any detail.

As shown, similar to the embodiment described above, an initialdownstream component 202 of the processing equipment is configured toinitially receive the multi-layer panel material assembly 80 (e.g., asrepresented by the elongated strip shown in FIG. 7 extending along thelength of the processing path in the processing direction, as indicatedby arrows 112). For instance, the downstream component 202 may bepositioned downstream of the press wheels 110 (FIGS. 3-5) such that thepanel material assembly 80 is continuously drawn from its formationalong the processing path in the processing direction 112. Thus, as adownstream portion of the panel material assembly 80 is being drawnthrough the downstream component 202 (and the remainder of theprocessing equipment along the processing path), an upstream portion ofthe panel material assembly 80 is simultaneously being formed as part ofthe continuous, stream-lined process. As indicated above, in oneembodiment, the downstream component 202 may correspond to astrip-coupling apparatus configured to couple the end of one panelmaterial assembly to the beginning of another panel material assembly,as desired or needed, thereby enabling the material assembly to becontinuously fed along the processing path from one station (or piece ofequipment) to another. It should be appreciated that, although FIG. 7illustrates an embodiment of the in-line process 200′ in which the panelmaterial assembly 80 is drawn through a continuous sequence ofprocessing equipment to form the desired panel, the various processingsteps or operations associated with the in-line process 200 may,instead, be performed using a non-continuous or interrupted sequence ofprocessing equipment.

Additionally, the panel material assembly 80 is pulled through theheated mold by a pulling device 204, which may include rollers havingfeatures or elements which grip and pull the material, such as spikes ora high friction material, such as rubber or sand paper, on the rollersurface. In one embodiment, in order to minimize stretching of thematerial, the pulling force exerted on the material assembly 80 by thepulling device 204 is carefully controlled. Moreover, an optional buffer(accumulator) 206 may be provided to readily enable the panel materialassembly 80 to be passed through the heated mold at a constant speed,regardless of whether separate material assemblies are in the process ofbeing joined together or not. In one embodiment, the material assembly80 is pulled through the buffer 206 by the pulling rollers 208 a, 208 b,210, 212 a, 212 b which may incorporate small spikes or a high frictionmaterial, such as rubber or sand paper, on the roller surface or otherfeatures or elements to grip and pull the material.

In the illustrated embodiment, an optional metal detection unit 270 mayalso be provided for detecting, for example, needles or broken needletips which are present in the panel material assembly 80. Where themetal detection unit is provided, there may also be provided a needlemarking unit 272 for marking for identification purposes the location ofa metal piece in the panel material assembly 80. The marking unit maycomprise a pen or may comprise a stamping device or an inking device,for example. Such a metal detection unit and marking unit could also beprovided in any of the other various embodiments of the disclosedprocess/equipment described herein.

Optionally, a branding unit 274 may also be provided to add logos orother designs, patterns, and/or indicia to the panel material assembly80 as it passes along the processing path through the related equipment.Again, such a branding unit could also be provided in any of the othervarious embodiments of the disclosed process/equipment described herein.

As shown in FIG. 7, a pre-heating unit 280 is provided that includes anair heater and an air blower. The air is heated by the air heater andthen blown onto the surface of the panel material assembly 80 as itpasses through the pre-heating unit 280. In one embodiment, the heatedair is able to rapidly heat the material assembly 80 as it passesthrough to a given temperature, such as to a processing temperature ator around the forming and temperature of the inner material layer of thematerial assembly 80 (but below the forming temperature of the outermaterial layer of the material assembly 80). In one embodiment, the airmay exit the air heater at a higher temperature than the temperature towhich the panel material assembly is being heated 80. In other examples,the air heated by the air heater may be sucked through the panelmaterial assembly 80 as it passes through the pre-heating unit 280.Additionally, in one embodiment, the temperature of the panel materialassembly 80 may be monitored as it passes through the pre-heating unit280 and the temperature and/or speed of the air flow and/or the speed ofthe material assembly 80 may be adjusted to maintain the temperature ofthe material assembly 80 at a desired level to provide consistent,uniform heating thereof.

The pre-heated panel material assembly 80 is then drawn into the heatedmold 282. In this example, the mold is an oil-heated mold similar tothat described above with reference to FIG. 6. In one embodiment, theheated mold 282 maintains the temperature of the panel material assembly80 at given temperature selected, for example, based on the materialproperties of the inner material layer as it passes through the heatedmold. Optionally, a further pre-heating mold may be provided before theheated mold 282 if the pre-heating unit 280 does not provide sufficientheat.

In one embodiment, the heated mold 282 comprises a plurality of formblocks 283, examples of which are shown in FIG. 8. The form blocks 283are able to be fitted into and removed from the heated mold 282, and actto gradually deform the heated panel material assembly 80 as it passesthrough each form block. Specifically, the portion of the panel materialassembly 80 entering the heated mold 282 passes through each of the formblocks in turn in the processing direction (e.g., as indicated by arrow112 in FIG. 8), with each form block further deforming the panelmaterial assembly 80 so that it leaves the heated mold in the form of alinear panel having the desired shape (e.g., the shape of the die of thefinal form block). If desired, the form blocks may be provided withguided surfaces to further assist the guidance of the panel materialassembly 80 through the form blocks.

Referring back to FIG. 7, a cooling unit 284 is provided downstream ofthe heated mold 282. The cooling unit may, for example, comprise an airpump and a heat exchanger for cooling the air. In other embodiments, thecooling unit may not require a heat exchanger if air at ambienttemperature is to be used rather than cooled air. The cooled or ambientair is sucked through the panel material assembly 80 as it passesthrough the cooling unit. In other examples, the cooled or ambient airmay be blown onto the panel material assembly 80 as it passes throughthe cooling unit. One or more cooling units may be provided such thatthe panel material assembly 80 exiting the cooling unit is lowered to afinal, desired temperature. This permits the material(s) of the innermaterial layer to be fixed into position and sets and stabilizes thefinal shape of the panel, ready for cutting to length.

In one embodiment, the cooling unit 284 may include one or more formblocks having cut-outs in the shape of the finished panel and beingspaced apart from each other, thereby allowing the cooling air to makecontact with and/or pass through the portions of the formed panelmaterial assembly extending between the form blocks. An example of sucha cooling unit is shown in FIG. 9. As can be seen in FIG. 9, the coolingunit 284 includes a form block holder 290 holding a plurality of formblocks 291. Each of the form blocks 291 has the same cut out shape 292for accommodating and maintaining the formed panel shape of theelongated material assembly 80 as it passes through the cooling unit.The air flow 293 is able to contact and/or pass through the panelmaterial assembly 80 where it is exposed between the form blocks as itis drawn through the cooling unit, thereby cooling the material assembly80. In one embodiment, the temperature of the material assembly 80 maybe monitored as it passes through the cooling unit and the temperatureand/or speed of the cooling air flow and/or the speed of the materialassembly may be adjusted to enable the temperature of the materialassembly to reach a desired level upon exit from the cooling unit. Asindicated above, by the time the material assembly exits the coolingunit, it is preferably at a given exit temperature, such as atemperature well below the forming temperature of the inner materiallayer of the material assembly 80. In FIG. 9, there are approximately100 form blocks, each of approximately 6 mm thickness and with a spacingof approximately 10 mm between adjacent form blocks. However, the numberof form blocks, the thickness of the form blocks, and the spacingbetween the form blocks may be arranged as desired.

Once the panel has cooled, it is more readily pulled without unwantedstretching of the material and the pulling device 204 may be providedfor this purpose. As indicated above, the pulling device pulls thematerial assembly 80 through the processing equipment including thepre-heating unit, the forming mold and the cooling unit. In oneembodiment, the pulling device 204 may include two rollers, one locatedadjacent the other with the elongated panel material assembly 80 passingbetween the rollers, as shown in FIG. 7.

Alternatively, the pulling device may be configured as shown in FIG. 10.In the embodiment shown in FIG. 10, the pulling device includes threerollers 294, with each roller being arranged one after the other alongthe processing direction of the panel material assembly 80 and having asurface incorporating spikes or a rough surface, such as sandpaper, anda further roller, wheel or ball bearing 295 located adjacent each roller294. Although this example shows three rollers, there may be more orfewer rollers 294, each having an adjacent roller, wheel or ball bearing295. In such an embodiment, the panel material assembly 80 is pulledbetween the roller 294 and the adjacent roller, wheel, or ball bearing295 by the rotation of the roller 294. The roller, wheel, or ballbearing may have a smooth surface, in contrast to roller 294, and issupported by rod 296. The roller, wheel, or ball bearing 295 may bebiased towards the roller 294. The roller, wheel, or ball bearing 295acts to keep the panel material assembly 80 in contact with the roller294 so that rotation of the roller 294 acts to move the materialassembly 80 along in a linear direction approximately tangential to thesurface of the roller 294, thereby pulling the material assembly throughthe pre-heating, molding, and cooling apparatus.

Referring back to FIG. 7, an optional distance counting unit 287 mayalso be provided. The distance counting unit ensures that the panels arecut at an equal, desired length. Moreover, an optional weld recognitionunit 288 may be provided to identify the regions where two separatepanel material assemblies have been joined together, so that theseregions may be removed and do not form part of a finished panel. Such adistance counting unit and/or optical weld recognition unit could alsobe provided in any of the other embodiments of the process/equipmentdescribed herein.

Finally, as shown in FIG. 7, the cooled elongate panel may be cut intotwo or more panels of desired lengths by cutting unit 242, and a packingtable 244 may be provided at the downstream end of the processing path.

It should be appreciated that, similar to the embodiment described abovewith reference to FIG. 6, the processing equipment described withreference to FIG. 7 may be automatically controlled, for example, via asuitable controller or central control unit, such as the central controlunit 240 shown in FIG. 6.

Additionally, it should be appreciated that, as an alternative to usinga heated mold, the disclosed process for manufacturing linear panels mayutilize any other suitable manufacturing equipment and/or technique thatallows for a linear panel of desired shape and dimensions to be madeusing a multi-layer panel material assembly. For instance, in one ormore alternative embodiments, the panel described herein may be formedby a roll-forming process. For instance, the panel material assembly maybe initially heated to a given pre-heat temperature to provide thematerial with sufficient strength to be handled during the panelmanufacturing process and to prevent undue shrinkage when the materialis heated to a higher temperature during the panel-forming process. Inone embodiment, the material may be pre-heated to a pre-heat temperatureselected based on the specific material properties of the inner materiallayer of the material assembly. The edges of the panel material assemblymay then be bent or rolled-formed to a desired configuration (e.g., at abending station or any other suitable station). Thereafter, in oneembodiment, heat may be applied to the panel material assembly as it ispassed by rollers and, optionally, a mold, to form the remainder of thepanel material assembly into the desired shape. The panel materialassembly may then be cooled to set the final shape of the finishedpanel.

In one embodiment, pre-heating of the panel material assembly may beutilized to prevent or minimize material shrinkage. For instance, asindicated above, it may be desirable that any shrinkage of the materialduring formation of the linear panel is minimized as the dimensions ofthe finished panel should permit the panel to be successfully mountedonto a carrier. Additionally, in order to control the effects of anyfurther shrinking of the panel material assembly during manufacture ofthe panel, the temperature to which the material assembly is heated andthe speed at which the material assembly proceeds through the rollers ispreferably accurately controlled during the panel manufacturing process

Referring now to FIG. 11, a schematic view of one embodiment of anin-line process and related processing equipment (generally designatedby 300) for manufacturing panels using a roll-forming process isillustrated in accordance with aspects of the present subject matter. Inthe illustrated embodiment, the process and related processing equipmentfor forming the multi-layer panel material assembly are indicatedschematically in FIG. 11 as a solid box labeled 100, 100′, 100*, withthe output of such process/equipment corresponding to the panel materialassembly 80 (e.g., including the inner and outer material layers). Itshould be appreciated that the specific process/equipment represented bybox 100, 100′, 100* may generally correspond to any suitableprocess/equipment consistent with the disclosure provided herein, suchas any of the embodiments shown in FIGS. 3-5.

As shown, the previously formed multi-layer panel material assembly 80(e.g., as represented by the elongated strip shown in FIG. 11 extendingalong the length of the processing path in the processing direction, asindicated by arrow 112) is configured to be drawn through correspondingroll-forming machinery 302. For instance, the roll-forming machinery 302may be positioned downstream of the press wheels 110 (FIGS. 3-5) suchthat the panel material assembly 80 is drawn from its formation alongthe processing path in the processing direction 112. Thus, as adownstream portion of the panel material assembly 80 is being drawnthrough the roll-forming machinery 302 (and the remainder of any otherprocessing equipment along the processing path), an upstream portion ofthe panel material assembly 80 is simultaneously being formed as part ofthe continuous, stream-lined process. It should be appreciated that,although the in-line process 300 will generally be described herein ascorresponding to a process in which the panel material assembly 80 isdrawn through a continuous sequence of processing equipment to form thedesired panel, the various processing steps or operations associatedwith the in-line process 300 may, instead, be performed using anon-continuous or interrupted sequence of processing equipment.

Rollers (not shown), which may include small spikes, form part of theroll-forming machinery 302 and may be used to grip and pull the panelmaterial assembly 80 through the machinery 392. As indicated above,under the influence of these pulling forces, the material may stretch,thereby affecting the thickness, stiffness, and straightness of thefinished panel. It is therefore advantageous to accurately control thepulling force exerted on the panel material assembly 80 during theroll-forming process.

In one embodiment, the elongate edges of the panel material assembly 80may be initially pre-heated to a given temperature selected based on thematerial properties of the inner material layer of the material assembly80, such as a specific pre-heat temperature selected so as to permit thefinished panel to retain its shape while minimizing the risk of undueshrinking and enabling the outer material layer of the material assembly80 to retain its fibrous, felt-like appearance.

In one embodiment, a heating device 304 a, 304 b, such as those depictedin FIG. 12, may touch or be provided adjacent or spaced from the edgesof the panel material assembly 80 in order to heat the edges as thematerial assembly 80 passes the heating device 304 a, 304 b. The heatingdevice 304 a, 304 b may blow hot air onto the edges of the panelmaterial assembly 80 (or suck hot air through the edges of the materialassembly 80), or may radiate heat in the form of infrared radiationthereon, for example. Alternatively, the heating device 304 a, 304 b mayitself be heated and may conduct this heat to the passing materialassembly 80, for example in a manner similar to an iron.

The heated edges of the panel material assembly 80 are then directed toa bending station 306, an example of which is shown in FIG. 13, wherethe edges of the material assembly 80 may be bent to a desiredconfiguration. In one embodiment, rollers 308 a, 308 b are used to bendthe edges about approximately 90° to produce a flange across eachelongate side of the panel material assembly 80. In addition, the panelmaterial assembly 80 may then pass bending blocks 310 a, 310 bconfigured to bend the edges still further. In one embodiment, thebending blocks may be configured to further bend the edges from theangle of approximately 90° an amount greater than or equal to 20° and/orless than or equal to 70°, including any other angles definedtherebetween in increments of 5°. In another embodiment, the bendingblocks may be configured to further bend the edges from the angle ofapproximately 90° an amount greater than or equal to 35° and/or lessthan or equal to 55°, including any other angles defined therebetween inincrements of 5°.

Where the panel is to be provided in the form of a baffle, and it isdesigned to hang from a carrier from one elongate side, no furtherbending of the panel may be necessary. However, where the panel isintended to have a substantially “U”-shaped cross-section (e.g., similarto that shown in FIGS. 1 and 2), and to hang from the carrier from bothelongate sides of the panel, further bending of the panel materialassembly 80 may be desirable. To achieve this, a further heating station312, such as that shown in FIG. 14, is provided. At heating station 312,heat is provided to a roller 314 which passes over the elongate centralpanel wall 52 (FIG. 1) of the panel material assembly 80. The materialassembly 80 then passes through a further bending station 316 whichcomprises two rollers 318 a, 318 b which cause the elongate edges of theelongate central portion to bend through approximately 90°. Thisprovides the panel with a substantially “U”-shaped cross-section, suchas that described above with references to FIGS. 1 and 2.

Following the formation of an elongated panel as described above, theelongated panel may optionally be passed through a mold 330 as depictedin FIGS. 15 and 16. FIG. 16 shows an end view of the mold 330. Bypassing the elongate panel through mold 330, the shape of the panel canbe more accurately controlled. The mold 330 does not need to be heated,but low temperature heating of the mold may be advantageous to enableeven greater control of the shrinkage of the panel material andtherefore the shape of the finished panel.

Additionally, following formation of the panel, the panel materialassembly is cooled. In one embodiment, the panel material assemblypasses through a cooling stage where it may be cooled, for example, bychilled air or by air at ambient temperature. Active cooling, such asdirecting ambient or chilled air onto or through the panel materialassembly 80 or passing the material assembly 80 through a cooled mold,may be employed. FIG. 17 shows one example of a cooling station orequipment for cooling the panel material assembly 80. In FIG. 17, thematerial is cooled via ambient air. During this cooling process, theelongated material assembly 80 is supported in a “U”-shaped channel 342.A roller 344 may be optionally provided to press and maintain theflanges of the panel (e.g., flanges 62, 64 of the panel 50 shown inFIGS. 1 and 2) in position and prevent them from springing back to theiroriginal pre-formed position when the material assembly 80 is cooled.The panel typically needs to be sufficiently cooled in order to fix thematerial(s) of the inner material layer of the material assembly 80 intoposition and thereby set the final shape of the finished panel.

Similar to the embodiment described above, the cooling process (asindeed the heating process) may be dependent upon the speed at which thematerial assembly 80 is fed through the cooling (or heating) stages. Forexample, in one embodiment, at speeds of approximately 2 meters/minute,passing the material assembly 80 through ambient air generally should besufficient to permit satisfactory cooling of the material. However, atfaster speeds of 10 to 20 meters/minute, cooled air may need to be blowndirectly onto or sucked through the panel material assembly 80 in orderto achieve satisfactory cooling of the material assembly. Alternatively,the material assembly 80 could instead be passed through a chilled mold.It should be appreciated that, in addition to the speed at which thematerial assembly 80 is fed through the cooling (or heating stages), theactual length of such stage(s) may also impact the cooling (or heating)process. For instance, for a longer cooling stage, ambient air may beused for cooling at faster processing speeds than for a significantlyshorter cooling stage.

Finally, once cooled, the elongate panel formed by the disclosed processmay be cut into desired lengths. Depending on the desired use of thepanels, the lengths will generally vary. However, in one embodiment, thepanel length will generally be on the order of greater than or equal to0.5 meters and/or less than or equal to 6 meters, including any lengthsdefined therebetween in increments of 0.25 meter.

It should be appreciated that, in general, the use of heated molds androll-forming techniques have been described herein as forming part ofseparate processing methods. However, in alternative embodiments, acombination of roll-forming techniques and heated molds may be used inthe manufacture of the linear panels.

While the foregoing Detailed Description and drawings represent variousembodiments, it will be understood that various additions,modifications, and substitutions may be made therein without departingfrom the spirit and scope of the present subject matter. Each example isprovided by way of explanation without intent to limit the broadconcepts of the present subject matter. In particular, it will be clearto those skilled in the art that principles of the present disclosuremay be embodied in other forms, structures, arrangements, proportions,and with other elements, materials, and components, without departingfrom the spirit or essential characteristics thereof. For instance,features illustrated or described as part of one embodiment can be usedwith another embodiment to yield a still further embodiment. Thus, it isintended that the present subject matter covers such modifications andvariations as come within the scope of the appended claims and theirequivalents. One skilled in the art will appreciate that the disclosuremay be used with many modifications of structure, arrangement,proportions, materials, and components and otherwise, used in thepractice of the disclosure, which are particularly adapted to specificenvironments and operative requirements without departing from theprinciples of the present subject matter. For example, elements shown asintegrally formed may be constructed of multiple parts or elements shownas multiple parts may be integrally formed, the operation of elementsmay be reversed or otherwise varied, the size or dimensions of theelements may be varied. The presently disclosed embodiments aretherefore to be considered in all respects as illustrative and notrestrictive, the scope of the present subject matter being indicated bythe appended claims, and not limited to the foregoing description.

In the foregoing Detailed Description, it will be appreciated that thephrases “at least one”, “one or more”, and “and/or”, as used herein, areopen-ended expressions that are both conjunctive and disjunctive inoperation. The term “a” or “an” element, as used herein, refers to oneor more of that element. As such, the terms “a” (or “an”), “one or more”and “at least one” can be used interchangeably herein. All directionalreferences (e.g., proximal, distal, upper, lower, upward, downward,left, right, lateral, longitudinal, front, rear, top, bottom, above,below, vertical, horizontal, cross-wise, radial, axial, clockwise,counterclockwise, and/or the like) are only used for identificationpurposes to aid the reader's understanding of the present subjectmatter, and/or serve to distinguish regions of the associated elementsfrom one another, and do not limit the associated element, particularlyas to the position, orientation, or use of the present subject matter.Connection references (e.g., attached, coupled, connected, joined,secured, mounted and/or the like) are to be construed broadly and mayinclude intermediate members between a collection of elements andrelative movement between elements unless otherwise indicated. As such,connection references do not necessarily infer that two elements aredirectly connected and in fixed relation to each other. Identificationreferences (e.g., primary, secondary, first, second, third, fourth,etc.) are not intended to connote importance or priority, but are usedto distinguish one feature from another.

All apparatuses and methods disclosed herein are examples of apparatusesand/or methods implemented in accordance with one or more principles ofthe present subject matter. These examples are not the only way toimplement these principles but are merely examples. Thus, references toelements or structures or features in the drawings must be appreciatedas references to examples of embodiments of the present subject matter,and should not be understood as limiting the disclosure to the specificelements, structures, or features illustrated. Other examples of mannersof implementing the disclosed principles will occur to a person ofordinary skill in the art upon reading this disclosure.

This written description uses examples to disclose the present subjectmatter, including the best mode, and also to enable any person skilledin the art to practice the present subject matter, including making andusing any devices or systems and performing any incorporated methods.The patentable scope of the present subject matter is defined by theclaims, and may include other examples that occur to those skilled inthe art. Such other examples are intended to be within the scope of theclaims if they include structural elements that do not differ from theliteral language of the claims, or if they include equivalent structuralelements with insubstantial differences from the literal languages ofthe claims.

The following claims are hereby incorporated into this DetailedDescription by this reference, with each claim standing on its own as aseparate embodiment of the present disclosure. In the claims, the term“comprises/comprising” does not exclude the presence of other elementsor steps. Furthermore, although individually listed, a plurality ofmeans, elements or method steps may be implemented by, e.g., a singleunit or processor. Additionally, although individual features may beincluded in different claims, these may possibly advantageously becombined, and the inclusion in different claims does not imply that acombination of features is not feasible and/or advantageous. Inaddition, singular references do not exclude a plurality. The terms “a”,“an”, “first”, “second”, etc., do not preclude a plurality. Referencesigns in the claims are provided merely as a clarifying example andshall not be construed as limiting the scope of the claims in any way.

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 18. A linear panel, comprising: a body including a panel wall and first and second sidewalls extending outwardly from the panel wall, the body being formed from a multi-layer panel assembly including an inner material layer and an outer material layer, the inner material layer defining an inner surface of the body, the outer material layer defining an outer surface of the body; wherein the inner material layer is formed from a material having a forming temperature that is less than a forming temperature of a material used to form the outer material layer.
 19. The linear panel of claim 18, wherein the material of the outer material layer comprises a fibrous felt material.
 20. The linear panel of claim 18, wherein the material of the inner material layer comprises a thermoformable fibrous material or a thermoformable film material.
 21. The linear panel of claim 20, wherein the thermoformable fibrous material is formed from a material selected from the group consisting of a woven material formed at least partially from synthetic fibers, a non-woven material formed at least partially from synthetic fibers, and a perforated polymer film material.
 22. The linear panel of claim 18, wherein the material of the outer material layer comprises a fibrous material.
 23. The linear panel of claim 21, wherein the fibrous material comprises a non-woven or woven fibrous material formed at least partially from synthetic or natural fibers.
 24. The linear panel of claim 18, wherein: first sides of each of the panel wall, first sidewall, and second sidewall define the inner surface of the body and opposed second sides of each of the panel wall, first sidewall and second sidewall define the outer surface of the panel body; the inner material layer extends along the first sides of each of the panel wall, first sidewall, and second sidewall to form the inner surface of the panel body; and the outer material layer extends along the opposed second sides of each of the panel wall, first sidewall, and second sidewall to form the outer surface of the panel body.
 25. The linear panel of claim 18, wherein each of the first and second sidewalls is bent at an edge portion of the body to form respective first and second flanges.
 26. The linear panel of claim 25, wherein the first flange extends at least partially from the first sidewall towards the second sidewall and wherein the second flange extends at least partially from the second sidewall towards the first sidewall.
 27. The linear panel of claim 18, wherein a thickness ratio of a thickness of the inner material layer to a thickness of the outer material layer ranges from greater than 1:1 to less than 4:1.
 28. The linear panel of claim 18, wherein the inner and outer material layers comprise separate strips of material that are coupled together to form the multi-layer panel assembly. 